Thermoplastic compositions, method of manufacture, and articles therefrom

Abstract

A thermoplastic composition including a polycarbonatesiloxane-arylate; a phthalone compound; and optionally an additional component different from the polycarbonatesiloxane-arylate and the phthalone compound; wherein the phthalone compound has a formula: wherein Z 1 represents the atoms necessary to complete a 9- to 13-membered single or fused aromatic ring structure, Z 2 represents the atoms necessary to complete a pyridine or quinoline ring, each R 1 and each R 2 are independently halogen, an alkyl group, an aryl group, a heterocyclic group, an alkoxy group, an aryloxy group, an aromatic or aliphatic thioether group, an aromatic or aliphatic carboxylic acid ester group, or an aromatic or aliphatic amide group, a is an integer from 0 to 6, b is an integer from 0 to 4, n is 1 or 2, and X is present only if n=2 and is a single bond or a divalent organic radical bonded to the Z 1 ring structure through an ether, ketone, or thio linkage.

The invention claimed is: 
     
       1. A thermoplastic composition comprising
 a polycarbonatesiloxane-arylate; 
 0.001 wt % to 0.14 wt % of a phthalone compound based on the total weight of the thermoplastic composition; and 
 optionally an additional component different from the polycarbonatesiloxane-arylate and the phthalone compound; 
 wherein the phthalone compound has a formula: 
 
       
         
           
           
               
               
           
         
         wherein 
         Z 1  represents the atoms necessary to complete a 9- to 13-membered single aromatic ring structure or a 9- to 13-membered fused aromatic ring structure, 
         Z 2  represents the atoms necessary to complete a pyridine or quinoline ring, 
         each R 1  and each R 2  are independently halogen, an alkyl group, an aryl group, a heterocyclic group, an alkoxy group, an aryloxy group, an aromatic or aliphatic thioether group, an aromatic or aliphatic carboxylic acid ester group, or an aromatic or aliphatic amide group, 
         a is an integer from 0 to 6, 
         b is an integer from 0 to 4, 
         n is 1 or 2, and 
         X is present only if n=2, and is a single bond or a divalent organic radical bonded to the Z 1  ring structure through an ether, ketone, or thio linkage. 
       
     
     
       2. The thermoplastic composition of  claim 1 , wherein the polycarbonatesiloxane-arylate comprises
 0.2 to 10 wt % siloxane units, 
 50 to 99.6 wt % arylate units, and 
 0.2 to 49.8 wt % carbonate units, 
 each based on the weight of the polycarbonatesiloxane-arylate. 
 
     
     
       3. The thermoplastic composition of  claim 2 , wherein
 the carbonate units are bisphenol A carbonate units, resorcinol carbonate units, or a combination thereof; 
 the arylate ester units are isophthalic acid-terephthalic acid-resorcinol units; and 
 the siloxane units are of the formula 
 
       
         
           
           
               
               
           
         
       
       or a combination comprising at least one of the foregoing siloxane units, wherein
 R is each independently a C 1-13  monovalent hydrocarbon group, 
 Ar is each independently a C 6 -C 30  aromatic group, 
 R 5  is each independently a C 2-14  hydrocarbylene group, and 
 E has an average value of 2 to 200. 
 
     
     
       4. The thermoplastic composition of  claim 2 , wherein the siloxane units are of the formula 
       
         
           
           
               
               
           
         
         or a combination comprising at least one of the foregoing, wherein E has an average value of 2 to 200. 
       
     
     
       5. The thermoplastic composition of  claim 1 , wherein the phthalone compound is according to the formula: 
       
         
           
           
               
               
           
         
         wherein 
         R 1.1 , R 1.2 , R 1.3 , R 1.4 , R 2.1 , R 2.2 , R 2.3 , and R 2.4  are each independently hydrogen, halogen, a C 1 -C 18  alkyl group, a C 6 -C 12  aryl group, a C 1 -C 18  alkoxy group, or a C 6 -C 12  aryloxy group, 
         n is 1 or 2, and 
         X is present in place of one of R 1.1 , R 1.2 , R 1.3 , or R 1.4  when n is 2. 
       
     
     
       6. The thermoplastic composition of  claim 1 , wherein the phthalone compound is according to the formula 
       
         
           
           
               
               
           
         
         wherein 
         R 1.1 , R 1.2 , R 1.3 , R 1.4 , R 2.1 , R 2.2 , R 2.3 , and R 2.4  are each independently hydrogen, halogen, a C 1 -C 18  alkyl group, a C 6 -C 12  aryl group, a C 1 -C 18  alkoxy group, or a C 6 -C 12  aryloxy group. 
       
     
     
       7. The thermoplastic composition of  claim 1 , wherein the phthalone compound is according to the formula: 
       
         
           
           
               
               
           
         
         wherein
 R 1.1 , R 1.2 , R 1.3 , R 1.4 , R 1.5 , R 1.6 , R 2.1 , R 2.2 , R 2.3 , and R 2.4  are each independently hydrogen, halogen, a C 1 -C 18  alkyl group, a C 6 -C 12  aryl group, a C 1 -C 18  alkoxy group, or a C 6 -C 12  aryloxy group, 
 n is 1 or 2, and 
 X is present in place of one of R 1.1 , R 1.2 , R 1.3 , R 1.4 , R 1.5 , or R 1.6 , when n is 2. 
 
       
     
     
       8. The thermoplastic composition of  claim 1 , wherein the phthalone compound is 
       
         
           
           
               
               
           
         
         or a combination comprising at least one of the foregoing. 
       
     
     
       9. The thermoplastic composition of  claim 1 , comprising 0.02 to 0.08 wt. % of the phthalone compound, based on the total weight of the thermoplastic compositions. 
     
     
       10. The thermoplastic composition of  claim 1 , wherein the composition comprises the additional component; and wherein the additional component comprises a polycarbonate, a polyetherimide, an organophosphorus compound, or a combination comprising at least one of the foregoing. 
     
     
       11. The thermoplastic composition of  claim 10 , wherein the polycarbonate is a poly(carbonate-monoaryl arylate ester) comprising
 repeating carbonate units of the formula 
 
       
         
           
           
               
               
           
         
         wherein
 R a  and R b  are each independently are each independently C 1-12  alkyl, 
 p and q are each independently integers of 0 to 4, and 
 X a  is a single bond, —O—, —S—, —S(O)—, —S(O) 2 —, —C(O)—, or a C 1-18  organic group; and 
 
         monoarylate ester units of the formula 
       
       
         
           
           
               
               
           
         
         wherein
 R h  is each independently a halogen or C 1-10  hydrocarbon group, and 
 n is 0 to 4. 
 
       
     
     
       12. The thermoplastic composition of  claim 11 , wherein the poly(carbonate-monoaryl arylate ester) is a poly(bisphenol-A carbonate)-co-poly(isophthalate-terephthalate-resorcinol), comprising 1 to 20 mol % of bisphenol A carbonate units, 20-98 mol % of isophthalic acid-terephthalic acid-resorcinol ester units, and optionally 1 to 60 mol % of resorcinol carbonate units, isophthalic acid-terephthalic acid-bisphenol A phthalate ester units, or a combination thereof. 
     
     
       13. The thermoplastic composition of  claim 10 , wherein the composition further comprises 5 wt % to 60 wt %, based on the total weight of the polymers in the thermoplastic composition, a polyetherimide having the formula 
       
         
           
           
               
               
           
         
         wherein
 R is a C 2-20  hydrocarbon group, and 
 Z is an aromatic C 6-24  monocyclic or polycyclic group optionally substituted with 1 to 6 C 1-8  alkyl groups, 1 to 8 halogen atoms, or a combination thereof, wherein the divalent bonds of the —O—Z—O— group are in the 3,3′, 3,4′, 4,3′, or the 4,4′ positions. 
 
       
     
     
       14. The thermoplastic composition of  claim 10 , wherein the organophosphorus compound is an aromatic organophosphorus compound having at least one organic aromatic group and at least one phosphorus-containing group, or an organic compound having at least one phosphorus-nitrogen bond. 
     
     
       15. The thermoplastic composition of  claim 1  wherein the composition comprises 0.01 wt % to 5 wt % of an additive composition comprising an additive selected from a processing aid, a heat stabilizer, an ultra violet light absorber, a colorant, or a combination comprising at least one of the foregoing, based on the total weight of the thermoplastic composition. 
     
     
       16. The thermoplastic composition of  claim 1 , wherein a sample of the composition has at least one of the following properties:
 i) a flame time of less than 15 seconds, a burn length of less than 8 inches, and a drip distinguishing time of less than 5 seconds, each measure using the method of FAR 25-853(a)(l)(ii) at a thickness of 1.5 mm; 
 ii) an average peak smoke density within 4-minute equal to or less than 200 as regulated by FAR 25-853(d); an average peak smoke density within 4-minute equal to or less than 150 as regulated by airbus ABD0031/ATS1000; 
 iii) a smoke extracted from a NBS smoke chamber and measured by Draeger tube having an average concentration of the following gas components: HF<100 ppm, HCl<150 ppm, HCN<150 ppm, SO 2 /H 2 S<100 ppm, NO/NO 2 <100 ppm, and CO<1000 ppm; 
 iv) a 2 minute integrated heat release rate of less than or equal to 65 kilowatt-minutes per square meter (kW-min/m 2 ) and a peak heat release rate of less than 65 kilowatts per square meter (kW/m 2 ) as measured using the method according to Part IV, OSU Heat Release of FAR/JAR 25.853, Amendment 25-116, 
 v) a smoke density after 4 minutes (Ds-4) of equal to or less than 300 measured in accordance with ISO 5659-2 on a 3 mm thick plaque, 
 vi) an integral of the smoke density as a function of time up to 4 minutes (VOF4) of equal to or less than 600 measured in accordance with ISO 5659-2 on a 3 mm thick plaque at 50 kW/m 2 , or 
 vii) a maximum average heat release (MAHRE) of equal to or less than 90 kW/m 2  measured in accordance with ISO 5660-1 on a 3 mm thick plaque at 50 kW/m 2 . 
 
     
     
       17. An article comprising the composition of  claim 1 , selected from a molded article, a thermoformed article, an extruded film, an extruded sheet, a foamed article, a layer of a multi-layer article, a substrate for a coated article, and a substrate for a metallized article. 
     
     
       18. The article of  claim 17 , selected from a train or aircraft interior component, wherein the component is a seat component, an interior vertical surface selected from side walls, front walls, end-walls, room dividers, partitions, flaps, boxes, hoods, mirrors, lighting covers, a panel in an electrochromic window, an enclosure for an electronic device, a display screen, a protective cover for a display screen, a display unit, a television, a refrigerator door, a tray table, a trolley panel, a food cart, a magazine rack, and louvres; an interior door or lining for internal and external doors; a window insulation; a kitchen interior surface; an interior horizontal surface selected from ceiling paneling, flaps, boxes, hoods and louvres; a luggage storage area selected from overhead and vertical luggage racks, luggage containers and compartments; a driver's desk application selected from paneling and surfaces of driver's desk; an interior surface of gangways selected from interior sides of gangway membranes (bellows) and interior linings; a window frame; an optionally folding table with downward facing surface; an interior or exterior surface of air ducts, or a device for passenger information. 
     
     
       19. A method of manufacture of an article, comprising molding, extruding, foaming, or casting the composition of  claim 1 . 
     
     
       20. A multilayer sheet or film comprising
 a base layer comprising a composition of  claim 1 ; and 
 a cap layer disposed on a side of the base layer, wherein the cap layer comprises poly(ethylene terephthalate), poly(vinyl fluoride), poly(vinylidene fluoride), or a combination comprising at least one of the foregoing; 
 wherein the multilayer sheet has at least of the following properties: 
 i) a flame time of less than 15 seconds, a burn length of less than 6 inches, and a drip extinguishing time of less than 5 seconds, each measured using the method of FAR F25.5, in accordance with FAR 25.853(a) at a thickness of 3 mm; 
 ii) a 2 minute integrated heat release rate of less than or equal to 65 kilowatt-minutes per square meter (kW-min/m 2 ) and a peak heat release rate of less than 65 kilowatts per square meter (kW/m 2 ) as measured using the method according to Part IV, OSU Heat Release of FAR/JAR 25.853, Amendment 25-116; 
 iii) a maximum averaged rate of heat emission of less than or equal to 90 kW/m2 with 50 kW/m2 irradiance level test condition according to ISO 5660-1; or 
 iv) at a thickness of 1.0 mm, a smoke density of less than or equal to 200 after four minutes of burning according to ASTM E662-06.